Copper ball bond features and structure

ABSTRACT

An integrated circuit wire bond connection is provided having an aluminum bond pad ( 51 ) that is directly bonded to a copper ball ( 52 ) to form an aluminum splash structure ( 53 ) and associated crevice opening ( 55 ) at a peripheral bond edge of the copper ball ( 54 ), where the aluminum splash structure ( 53 ) is characterized by a plurality of geometric properties indicative of a reliable copper ball bond, such as lateral splash size, splash shape, relative position of splash-ball crevice to the aluminum pad, crevice width, crevice length, crevice angle, and/or crevice-pad splash index.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 13/594,732,filed Aug. 24, 2012, now U.S. Pat. No. 8,907,485, issued Dec. 9, 2014,which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed in general to semiconductor devicesand methods for manufacturing same. In one aspect, the present inventionrelates to wire ball bonding and associated methods of fabricating andtesting same.

2. Description of the Related Art

Ball bonding is widely employed in the semiconductor packaging industryto form electrical connections between an integrated circuit die and adie carrier such as a lead frame or a substrate. Conventional ballbonding processes typically use a combination of heat, pressure andultrasonic energy to form an intermetallic connection or weld between awire and a connection pad. However, the connection pad is typicallysubjected to a number of stressors such as impact force, contact power,contact force, bond power and bond force during the ball bondingprocess, leading to mechanical integrity problems, such as cracksbetween the connection pad and bonding ball that can form duringbonding, device operation or device testing, such as highly acceleratedstress test (HAST). Such reliability concerns are exacerbated withcopper ball bonds which have a narrower process window than with goldball bonds.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention may be understood, and its numerous objects,features and advantages obtained, when the following detaileddescription is considered in conjunction with the following drawings, inwhich:

FIG. 1 is a top plan view of a semiconductor die edge having copperwirebonds affixed to bond pads, along with enlarged front and side viewsof a copper wirebond and bond pad structure in accordance with selectedembodiments;

FIG. 2 is a schematic cross section of a copper ball bond on an aluminumpad showing an aluminum splash formed on inner and outer segments ofball bond perimeter;

FIG. 3 is an enlarged schematic cross section of selected geometricfeatures of the aluminum splash and crevice formed at the interfacebetween a copper ball bond and aluminum pad;

FIG. 4 is an enlarged schematic cross section of geometric features fora crevice formed at the interface between a copper ball bond andaluminum pad;

FIG. 5 is an enlarged schematic cross section of a splash indexgeometric feature of the aluminum splash formed at the interface betweena copper ball bond and aluminum pad;

FIGS. 6-13 illustrate selected geometric features to different splashprofiles formed by copper ball bonds affixed to aluminum pads;

FIGS. 14-21 illustrate selected geometric features to different wavesplash profiles formed by copper ball bonds affixed to aluminum pads;

FIG. 22 illustrates additional geometric features to different splashprofiles formed by copper ball bonds affixed to aluminum pads; and

FIG. 23 is a simplified schematic flow chart illustrating variousmethods for fabricating copper ball bonds to meet a plurality ofcontrolled ball bond splash geometry features for a reliable ballbond-pad attachment.

It will be appreciated that for simplicity and clarity of illustration,elements illustrated in the drawings have not necessarily been drawn toscale. For example, the dimensions of some of the elements areexaggerated relative to other elements for purposes of promoting andimproving clarity and understanding. Further, where consideredappropriate, reference numerals have been repeated among the drawings torepresent corresponding or analogous elements.

DETAILED DESCRIPTION

A method and apparatus are described for forming reliable copper ballbonds on aluminum pads by controlling the bonding parameters to formaluminum splash features meeting a plurality of geometric structuralrequirements relating to the aluminum splash profile and the size andposition of the crevice or gap between the aluminum splash and copperball. In selected embodiments, the plurality of geometric structuralrequirements include the lateral splash size, splash shape, relativeposition of splash-ball crevice to the aluminum pad, crevice width,crevice length, crevice angle, and/or crevice-pad splash index. To formreliable copper ball bonds, the splash should be formed aroundsubstantially the entire perimeter of the ball bond and have a limitedextent beyond the perimeter of the ball bond. In addition, the elevatedsplash pad dimension (LB) should be less than or equal to twice theoutermost lateral splash length dimension (LS). Reliable copper ballbonds are also obtained when the splash-ball crevice is positioned abovethe top of the aluminum pad, thereby minimizing opportunities forundesirable mold compound penetration. In addition, short crevicelengths and narrow crevice widths reduce the probability of undesirablemold compound penetration. To prevent mold compound penetration, acontrolled crevice-pad splash index (β) defining an angle between thealuminum pad and the aluminum splash is controlled to be within apredetermined range (e.g., of 20-75°). Copper ball bonding reliabilityis also promoted by controlling the splash height (H_(P)) to be lessthan half the ball height and greater than half the aluminum padthickness. Other geometric structural features which may be used torealize reliable copper ball bonds include a crevice width, crevicelength, and crevice angle (α) defining an angle between the aluminum padand the aluminum splash, when these features are controlled to be withina predetermined range. The geometric features of the aluminum splash ondifferent copper ball bond perimeter regions are likely to be different,with larger aluminum splash on perimeter regions substantiallyperpendicular to the direction of ultrasonic vibration, and smalleraluminum splash on perimeter regions substantially parallel to thedirection of ultrasonic vibration. Consequently, the geometric featuresof the aluminum splash in copper ball bond cross-sections may beassessed in both perpendicular and parallel to the direction of theultrasonic vibration. The geometric features described hereinbelow applyto aluminum splash displayed in cross-sections through the center ofcopper ball bonds where the cross-sections were made in directions bothperpendicular and parallel to the direction of ultrasonic vibration.

Various illustrative embodiments of the present invention will now bedescribed in detail with reference to the accompanying figures. Whilevarious details are set forth in the following description, it will beappreciated that the present invention may be practiced without thesespecific details, and that numerous implementation-specific decisionsmay be made to the invention described herein to achieve the devicedesigner's specific goals, such as compliance with process technology ordesign-related constraints, which will vary from one implementation toanother. While such a development effort might be complex andtime-consuming, it would nevertheless be a routine undertaking for thoseof ordinary skill in the art having the benefit of this disclosure. Forexample, selected aspects are depicted with reference to simplifiedcross sectional drawings of an integrated circuit device with a copperwire ball bonded to a connection pad without including every devicefeature or geometry in order to avoid limiting or obscuring the presentinvention. Such descriptions and representations are used by thoseskilled in the art to describe and convey the substance of their work toothers skilled in the art. In addition, although specific examplematerials are described herein, those skilled in the art will recognizethat other materials with similar properties can be substituted withoutloss of function. It is also noted that, throughout this detaileddescription, certain materials will be deposited, grown, etched, maskedand/or removed to fabricate the semiconductor structure. Where thespecific procedures for forming or removing such materials are notdetailed below, conventional techniques to one skilled in the art forgrowing, depositing, removing or otherwise forming such layers atappropriate thicknesses shall be intended. Such details are well knownand not considered necessary to teach one skilled in the art of how tomake or use the present invention.

Referring now to FIG. 1, there is shown a top plan view 1 of asemiconductor die edge having copper wire bonds affixed to bond pads,along with enlarged front view 1A (along view lines A-A′) and side view1B (along view lines B-B′). As illustrated in the plan view 1, aplurality of bonding sites are formed on an integrated circuit die 12which may be attached to a die carrier (not shown) having a substrate ora lead frame. As integrated circuit dies, substrates, lead frames, andtheir respective bonding sites are known to those of ordinary skill inthe art, detailed descriptions thereof are not necessary for a fullunderstanding of the invention. On the IC die 12, there is formed one ormore connection pads 19-21, each of which may be formed as sensitive padstructures such as, for example, bond over active (BOA) pad structures,or bond pads formed over a low-k dielectric structure or via design. Inselected embodiments, the connection pads 19-21 may have a metalthickness of less than 1.5 μm, but may be ≧2.8 μm in thickness, and maybe formed with aluminum (Al) or other electrically conductive materialas is known in the art. It should however be understood by those ofskill in the art that the present invention is not limited by the typeor thickness or material used for the connection pads which will dependon the application.

A plurality of wire ball bond element 25-33 electrically connects theconnection pads 19-21 to external bonding sites (not shown). Forexample, a first wire bond—including a ball bond contact portion 25,interconnection portion 26 and wire conductor portion 27—is formed andaffixed to a first connection pad 19. In similar fashion, a second wirebond (including ball bond contact portion 28, interconnection portion29, and wire conductor portion 30) is attached to a second connectionpad 20, and a third wire bond (including ball bond contact portion 31,interconnection portion 32, and wire conductor portion 33) is attachedto a third connection pad 21. The wire bonds may be formed with copper(Cu) or other electrically conductive materials known in the art, suchas with gold (Au), aluminum (Al), and the like. Though illustrated asseparate portions, it will be appreciated that each wire bond may beformed as a single, integrated conductor.

To attach each wire bond to a corresponding connection pad (e.g., 19,20), a controlled ball bonding process uses a specified combination ofheat, pressure and ultrasonic energy to form an intermetallic connectionor weld between the wire bond and connection pad. In particular, thebonding process is controlled to form splash features 22-24 extendingfrom the connection pad at the base of the ball bond contact portionwhich have a predetermined splash profile and associated crevice or gapprofile between the splash feature and copper ball bond. As describedmore fully hereinbelow, a splash feature is formed when material fromthe connection pad is displaced by the ball bond during the bondingprocess so that at least part of the splash feature is raised orelevated above the original top surface of the connection pad. Topromote reliability, the splash feature should be formed aroundsubstantially the entire perimeter of the ball bond, though some shortbreaks in the continuity of the splash feature are acceptable. Inaddition, the splash feature should substantially extend to at least theperimeter of the ball bond but should not extend substantially past theperimeter of the ball bond

Depending on the specifics of the ball bonding process, the shape andextent of the splash feature may be different at different parts of theball bond perimeter. This is shown in the plan view 1 where theside-to-side direction 34 of the wire bond transducer movement duringthe ultrasonic ‘scrub’ portion of the Cu ball bonding process createssplash features 22-24 having a lateral extent that is greater in thedirection parallel to scrub motion than in the direction perpendicularto the scrub motion. The differences in lateral extent are clearly seenin the enlarged front view 1A of the first wire bond 25-27 andconnection pad 19 (along view lines A-A′) where the lateral extent ofthe splash feature 22 formed at the inner and outer segments of the ballbond extends past the perimeter of the ball bond contact portion 25. Incontrast, the enlarged front view of the wire bond 28-30 and connectionpad 20 (along view lines B-B′) shows that the lateral extent of thesplash feature 23 formed at the lateral segments of the ball bond doesnot quite extend to the perimeter of the ball bond contact portion 28,but nonetheless provides a minimum amount of splash.

In addition to controlling the lateral extent of the splash features,the bonding process parameters are applied to form splash featureshaving multiple geometric structural features relating to the aluminumsplash profile and the size and position of the crevice or gap betweenthe aluminum splash and copper ball. To illustrate the construction ofthe geometric structural features, reference is now made to FIG. 2 whichshows a schematic cross section view 2 of a copper ball bond 52 on analuminum bond pad 51 showing aluminum splash features 53-54 formed oninner and outer segments of ball bond perimeter to extend past theperimeter of the ball bond 52. The depicted cross-sectional view 2 isthrough the center of the ball bond 52 and parallel to the direction ofthe wire bond transducer movement during the ultrasonic scrub portion ofthe copper ball bonding process.

The bonding ball 52 may be a deformed ball bond characterized by a ballbond height dimension (HBall) measured from the original surface of thebond pad 51 to the top of the ball bond base, and a ball bond diameterdimension (DBall) measured across the lateral extent of the ball bondbase. In addition, the bond pad 51 is characterized by a bonding padthickness dimension (HPad). In selected embodiments, the bonding ball 52has a ball bond diameter dimension (DBall) of, for example, betweenabout 30-125 μm, and a predetermined ball bond height dimension (HBall)of, for example, between about 7-50 μm, though it will be appreciatedthat the dimensions of the preformed bonding ball 52 may depend on,among other things, the subsequent ball bond requirements, the wire typeemployed, the wire diameter, and the bonding process parameters such as,for example, the impact force applied. These dimensions may be combinedto form a ball bond ratio (BBR) parameter that is defined by the ratioof the ball bond height dimension (HBall) and the ball bond diameterdimension (DBall), where the BBR parameter should be in the range of18-35% to be optimized for copper wire bonding.

In addition to the dimensions of the bonding ball, there are othergeometric structural features at the interface between a copper ballbond and aluminum bond pad that have a significant impact on the ballbond reliability where properly optimized. To illustrate and define thecritical set of copper ball bond and aluminum pad geometrical featuresneeded for a reliable copper ball bond, reference is now made to FIG. 3which shows an enlarged schematic cross section view 3 of the area 57(shown in FIG. 2) to illustrate selected geometric features of thealuminum splash 53 interface with the copper ball bond 52 and aluminumpad 51. There are a number of geometric features characterizing thebonding interface between the copper ball 52 and aluminum bond pad 51,including an aluminum splash 53 that is formed to define a crevice 55with the copper ball bond 52.

A first geometric structural feature of the aluminum splash interface isthe lateral splash size of the aluminum splash 53. In FIG. 3, thelateral splash size is the length of region where the aluminum splash 53is raised above the top surface plane of the original aluminum pad 51.One way of measuring the lateral splash size is the lateral splashdistance (LS) from the crevice initiation point (X) to the outermostextent of a splash 53 that has an undercut region. The lateral splashsize may also be measured as the lateral base distance (LB) from thecrevice initiation point (X) to the furthest point where the displacedaluminum pad is elevated above the top surface plane of the originalaluminum pad. As will be appreciated, the lateral base dimension (LB)will exist with a splash that has an undercut (such as shown in FIG. 3),and also with splash that has no undercut (e.g., a gentle wave). In anyease, the bonding process should be controlled to form lateral aluminumsplash structures around substantially the entire perimeter of the ballbond 52, thereby providing a structural indication that the appliedbonding parameters have displaced pad aluminum to form a reliable bond.The desired size of the aluminum splash 53 will be a function of atleast the initial thickness and hardness of the aluminum pad 51. Inaddition, the bonding parameters are controlled so that the aluminumsplash 53 should extend substantially to, but not substantially past, atleast the perimeter of the ball bond 52. Generally, the lateral splashsize may be limited to extend no more than a predetermined distance(e.g., 5 μm) beyond the perimeter of the copper ball bond base 52,though this may be reduced (e.g., no more than 3 μm) when the ball bonddiameter DBall is constrained by a small bond pad opening. In selectedembodiments for forming reliable copper ball bonds, the elevated splashpad dimension (LB) should be less than or equal to twice the outermostlateral splash length dimension (LS).

Another geometric structural feature of the aluminum splash interface isthe shape of the aluminum splash 53. The aluminum splash can have aconcave shape which follows the curved shape of the copper ball 52, canhave a convex shape which curls or bends away from the curved shape ofthe copper ball 52, or can have an essentially linear or uncurvedprojection shape that extends linearly at any projection angle betweenthe shape of the copper ball 52 and the top surface plane of theoriginal aluminum pad 51. In general, the curvature of the upper surfaceof the splash feature that is closest to the copper ball determineswhether the shape is concave (e.g., curving with the curvature of thecopper ball) or convex (e.g., curving away front the curvature of thecopper ball).

An additional geometric structural feature of the aluminum splashinterface is the splash height to the top surface of the aluminum splash53. As shown in FIG. 3, one way of measuring the splash height is thevertical pad distance (H_(P)) from the original top surface plane of theoriginal aluminum pad 51 to the top surface of the aluminum splash 53.Another way of measuring the splash height is the vertical gap distance(H_(G)) from the horizontal plane of the crevice initiation point (X) tothe top surface of the aluminum splash 53. To promote reliable copperball bonding, the bonding process should be controlled so that thevertical pad distance (H_(P)) should be greater than 50% of the originalbonding pad thickness (HPad) and less than 50% of the ball bond height(HBall), respectively. In addition or in the alternative, bondreliability is promoted by controlling the bonding parameters to formthe aluminum splash 53 so that the vertical gap distance (H_(G)) is lessthan or equal to the vertical pad distance (H_(P)). In FIG. 3, thisrequirement is met since the horizontal plane of the crevice initiationpoint (X) is above the original top surface plane of the originalaluminum pad 51.

There are other geometric structural features relating to the size andshape of the crevice or gap 55 between the aluminum splash 53 and copperball 52, where the crevice 55 is characterized by crevice width, length,and angle features that are defined with reference to the creviceinitiation point X. The crevice features (width, length, and angle) maybe defined with a variety of different construction methods as describedherein, though it will be appreciated that other construction methodsmay be used to define essentially the same features by other methodsthat are intended to be included in and covered by this disclosure. Asshown in FIG. 3, a simplified method for constructing the crevice widthAB may be to draw a tangent line AB across both the aluminum splash 53(at tangent intersect point A) and copper ball 52 (at tangent intersectpoint B). Though not illustrated, the crevice width may instead beconstructed by a line drawn across the aluminum splash 53 tangentintersect point A and a vertical tangent point on the copper ball 52 (attangent intersect point B′). However the crevice width is defined, thecrevice length XC may be defined by drawing a line from the creviceinitiation point X to the midpoint C of the crevice width line (e.g.,AB). In addition, the crevice angle may be defined as the angle (α)between a first splash tangent line XA (drawn between the creviceinitiation point X and tangent intersect point A) and a second balltangent line XB (drawn between the crevice initiation point X andtangent intersect point B).

As indicated above, other construction methods may be used to define thecrevice features (width, length, and angle). For example, reference isnow made to FIG. 4 which shows an enlarged schematic cross section view4 of the copper bonding ball and aluminum splash area in the area 57(shown in FIG. 2) to illustrate the construction of a crevice width byfirst drawing a line from the crevice initiation point X through a firstsplash tangent intersect point D, creating line XD. Next, a second lineEH is drawn that intersects perpendicularly with line XD at intersectionpoint F, that is tangent with a second splash tangent intersect point E,and that intersects with copper ball intersect point H. In this example,the crevice width feature may be defined as the line segment EHextending between the second splash tangent intersect point E and thecopper ball intersect point H. Alternatively, the crevice width featuremay be defined as the line segment EH extending between theperpendicular intersection point F and the copper ball intersect pointH. However the crevice width is defined, the crevice length XG may bedefined by drawing a line from the crevice initiation point X to themidpoint G of the crevice width line (e.g., FH). In addition, thecrevice angle may be defined as the angle (α′) between a first splashtangent line XD (drawn between the crevice initiation point X andtangent intersect point D) and a second ball intersect line XH (drawnbetween the crevice initiation point X and copper ball intersect pointH).

To promote reliable copper ball bonding, the bonding process should becontrolled so that the crevice length is minimized, primarily by formingthe crevice 55 so that the crevice initiation point X is above the topsurface plane of the original aluminum pad 51. In addition, the crevicewidth should be minimized so as to reduce the probability of moldcompound penetrating an undesirable distance under the ball bond. Forlong crevices, it is preferred to have a small crevice angle, whilelarger crevice angles are acceptable for shorter crevices. In selectedembodiments, the crevice features should be formed so that the ratio ofthe crevice mouth width to crevice length is equal to or greater than0.1. In other embodiments and as described more fully hereinbelow withreference to FIG. 21, the crevice features may be formed so that theratio of the crevice width at the mid-point of the crevice to thecrevice mouth width falls within a specified range (e.g., approximately20%) to give an indication of the shape of the crevice which indicateshow rapidly the crevice narrows.

Another geometric structural feature relating to the formation ofreliable ball bonding is the crevice splash index angle of the aluminumsplash in relation to the aluminum pad which gives an indication of thecombined effects of the angle of the structure formed by the displacedAl (splash), and the shape and approximate angle of the crevice. Thecrevice splash index may be defined by construction method as shown inFIG. 5 which shows an enlarged schematic cross section view 5 of thecopper bonding ball and aluminum splash area in the area 57 shown inFIG. 2 to illustrate the construction of a crevice splash index angle,though it will be appreciated that other construction methods may beused to define essentially the same features by other methods that areintended to be included in and covered by this disclosure. As shown inFIG. 5, the splash index may be constructed by first defining a splashextension point M that is the perpendicular intersection betweenhorizontal and vertical tangent planes intersecting the aluminum splash53. In addition, a vertical crevice extension point N is defined that isthe perpendicular intersection between the top surface plane of theoriginal aluminum pad 51 and the vertical plane extending through thecrevice initiation point X. By drawing a splash extension line NMbetween the vertical crevice extension point N and the splash extensionpoint M, the crevice splash index may be defined as the angle (β)between the splash extension line NM and the top surface plane of theoriginal aluminum pad 51. The crevice splash index angle (β) provides astructural indication of the probability that subsequently injected moldcompound will penetrate an undesirable distance under the ball bond 52,and the resulting probability of pad damage (cratering) during bonding.The smaller the angle (β), the greater the probability of undesirablemold compound penetration, and the greater the angle (β) the greater theprobability of pad damage. With a small crevice splash index angle (β),the risk increases that mold compound may be forced with high pressureinto the crevice 55, causing stress on the underside of the ballperimeter that acts to peel the ball from the aluminum pad surface 51,also increasing risk that mold compound may penetrate under the ballbond 52 by moving into the crevice and through a discontinuousintermetallic bond phase between the copper ball 52 and the aluminum pad51 that is often present at the perimeter region of the ball bond. Inaddition, there is an increase in risk of cratering as the crevicesplash index angle (β) increases, even with good copper-aluminumbonding. To promote reliable copper ball bonding, the bonding processshould be controlled so that the crevice splash index angle (β) shouldbe between 20-75°, depending on the hardness and thickness of thealuminum pad 51.

To further illustrate how selected geometric features can be applied todifferent cases where splash profiles are formed by copper ball bondsaffixed to aluminum pads, reference is no made to FIGS. 6-13. In a firstcase shown in the cross-sectional view 6 of FIG. 6, a copper bond ball62 is bonded to the aluminum bonding pad 61 formed on the integratedcircuit die 60. The depicted bonding forms a small splash structure 63having a concave shape that extends from a crevice initiation point Xthat is located above the top plane N of the aluminum pad 61 (e.g.,H_(G)<H_(P)). To the extent that the lateral splash length dimension(LS) does not extend past the perimeter of the copper bond ball 62, thisis a relatively small splash structure 63. In addition, the resultingcrevice 65 formed between the copper bond ball 62 and splash structure63 has a relatively short crevice width AC, crevice angle α, and crevicelength X-Xd which characterize a reliable bond connection between thecopper bond ball 62 and aluminum bonding pad 61. In the exampleconstruction depicted in FIGS. 6-13, the crevice/ball bond dimension Dis the horizontal distance from the crevice initiation point X to theouter edge of the ball bond base 62 and the crevice/splash dimension Sis the horizontal distance from the crevice initiation point X to theouter edge of the aluminum splash 63. In addition, the crevice width ACis drawn along the tangent line KC (between aluminum splash tangentintersect point K and copper ball intersect point C and perpendicular tothe tangent line Xa which is drawn from the crevice point X through thealuminum splash tangent intersect point F), such that the crevice widthAC extends from point A (the intersection of lines KC and Xa) to point C(the copper ball intersect point from line KC). Alternatively, a crevicewidth KC dimension may be defined as the line drawn between aluminumsplash tangent intersect point K and copper ball intersect point C andperpendicular to the tangent line Xa which is drawn from the crevicepoint X through the aluminum splash tangent intersect point F. A crevicelength X-Xd dimension may also be defined as the line drawn from thecrevice point X to the midpoint Xd along the crevice width line AC. Thecrevice width α may be defined by angle FXC, or alternatively as theangle between tangent line Xa and tangent line Xb (drawn between thecrevice point X and the copper ball intersect point C).

In a second case shown in the cross-sectional view 7 of FIG. 7, a copperbond ball 7 is bonded to the aluminum bonding pad 71 formed on theintegrated circuit die 70. The depicted bonding forms a small splashstructure 73 having a concave shape that extends from a creviceinitiation point X that is located below the top plane N of the aluminumpad 71 (e.g., H_(P)<H_(G)). With the lateral splash length dimension(LS) not extending beyond the perimeter of the copper bond ball 72, thisis a relatively small splash structure 73. Compared to the first caseshown in FIG. 6, the crevice 75 formed between the copper bond ball 72and splash structure 73 has a relatively long crevice length X-Xd whichcharacterizes a relatively poor bond connection between the copper bondball 72 and aluminum bonding pad 71 due to the reduced bond interfacearea and increased likelihood of mold compound penetration under theball bond. In this example, the relatively long crevice between thealuminum splash structure 73 and copper bond ball 72, and extendingbelow the top plane N of the aluminum pad 71, characterizes anunreliable bond.

In a third case shown in the cross-sectional view 8 of FIG. 8, a copperbond ball 82 is bonded to the aluminum bonding pad 81 formed on theintegrated circuit die 80. The depicted bonding forms a small splashstructure 83 having a convex shape that extends from a creviceinitiation point X that is located above the top plane N of the aluminumpad 81 (e.g., H_(G)<H_(P)). With the lateral splash length dimension(LS) extending substantially to, but not past, the perimeter of thecopper bond ball 82, this is a relatively small splash structure 83.Although the crevice 85 formed between the copper bond ball 82 andsplash structure 83 has a relatively larger crevice width (e.g., KC orAC) and crevice angle α than the first case shown in FIG. 6, therelatively short crevice length X-Xd characterizes a relatively reliablebond connection between the copper bond ball 82 and aluminum bonding pad81.

In a fourth case shown in the cross-sectional view 9 of FIG. 9, a copperbond ball 92 is bonded to the aluminum bonding pad 91 formed on theintegrated circuit die 90. The depicted bonding forms a small splashstructure 93 having a convex shape that extends from a creviceinitiation point X that is located below the top plane N of the aluminumpad 91 (e.g., H_(P)<H_(G)). With the lateral splash length dimension(LS) extending substantially to, but not past, the perimeter of thecopper bond ball 92, this is a relatively small splash structure 93.Compared to the first case shown in FIG. 6, the crevice 95 formedbetween the copper bond ball 92 and splash structure 93 has a widercrevice width (e.g., KC or AC), larger crevice angle α, and longercrevice length X-Xd which characterize a relatively poor bond connectionbetween the copper bond ball 92 and aluminum bonding pad 91 due to thereduced bond interface area and increased likelihood of mold compoundpenetration under the ball bond. In this example, the relatively longcrevice 95 between the aluminum splash structure 93 and copper bond ball92 characterizes an unreliable bond.

In a fifth case shown in the cross-sectional view 10 of FIG. 10, acopper bond ball 102 is bonded to the aluminum bonding pad 101 formed onthe integrated circuit die 100. The depicted bonding forms a largesplash structure 103 having a concave shape that extends from a creviceinitiation point X that is located above the top plane N of the aluminumpad 101 (e.g., H_(G)<H_(P)). With the lateral splash length dimension(LS) extending past the perimeter of the copper bond ball 102, this is arelatively large splash structure 103. However, the lateral splashlength dimension (LS) should be limited to a maximum value to preventelectrical connection and shorting to adjacent bond pads. Although thecrevice 105 formed between the copper bond ball 102 and splash structure103 have a larger crevice width (e.g., KC or AC) and crevice angle αthan the first case shown in FIG. 6, the relatively short crevice lengthX-Xd characterizes a relatively reliable bond connection between thecopper bond ball 102 and aluminum bonding pad 101. In this example, therelatively shallow size of the crevice 105 between the aluminum splashstructure 103 and copper bond ball 102 characterizes a relativelyreliable bond.

In a sixth case shown in the cross-sectional view 11 of FIG. 11, acopper bond ball 112 is bonded to the aluminum bonding pad 111 formed onthe integrated circuit die 110. The depicted bonding forms a largesplash structure 113 having a concave shape that extends from a creviceinitiation point X that is located below the top plane N of the aluminumpad 91 (e.g., H_(P)<H_(G)). With the lateral splash length dimension(LS) extending past the perimeter of the copper bond ball 112, this is arelatively large splash structure 113. Compared to the fifth case shownin FIG. 10, the crevice 115 formed between the copper bond ball 112 andsplash structure 113 has a longer crevice width (e.g., KC or AC) whichcharacterizes a relatively poor bond connection between the copper bondball 112 and aluminum bonding pad 111 due to the reduced connection areaand increased likelihood of mold compound penetration under the ballbond. In this example, the relatively long crevice Xd for the crevice115 between the aluminum splash structure 113 and copper bond ball 112characterizes a less reliable bond than the fifth case.

In a seventh case shown in the cross-sectional view 12 of FIG. 12, acopper bond ball 122 is bonded to the aluminum bonding pad 121 formed onthe integrated circuit die 120. The depicted bonding forms a largesplash structure 123 having a convex shape that extends from a creviceinitiation point X that is located above the top plane N of the aluminumpad 121 (e.g., H_(G)<H_(P)). With the lateral splash length dimension(LS) extending past the perimeter of the copper bond ball 122, this is arelatively large splash structure 123. In the example constructiondepicted in FIGS. 12-13, the crevice width KC dimension may be definedas the tangent line KC extending from the outer or lateral most edgepoint C of the ball bond base 122 to the aluminum splash tangentintersect point K. With this construction, even though the crevice 125formed between the copper bond ball 122 and splash structure 123 hasrelatively large crevice width KC and crevice angle α (compared to thefirst case shown in FIG. 6), the location of the horizontal plane of thecrevice origin X above the top surface plane of the bonding pad 121characterizes a relatively reliable bond connection between the copperbond ball 122 and aluminum bonding pad 121, though less reliable thanthe first case shown in FIG. 6.

In an eighth case shown in the cross-sectional view 13 of FIG. 13, acopper bond ball 132 is bonded to the aluminum bonding pad 131 formed onthe integrated circuit die 130. The depicted bonding forms a largesplash structure 133 having a convex shape that extends from a creviceinitiation point X that is located below the top plane N of the aluminumpad 131 (e.g., H_(P)<H_(G)). With the lateral splash length dimension(LS) extending past the perimeter of the copper bond ball 132, this is arelatively large splash structure 133. Compared to the seventh caseshown in FIG. 12, the crevice 135 formed between the copper bond ball132 and splash structure 133 has a longer crevice length KC whichcharacterizes a relatively poor bond connection between the copper bondball 132 and aluminum bonding pad 131 due to the reduced bond interfacearea and increased likelihood of mold compound penetration under theball bond. In this example, the relatively long crevice length Xd forthe crevice 135 between the aluminum splash structure 133 and copperbond ball 132 characterizes an unreliable bond.

As seen from the foregoing, different geometric features may be definedfor different splash profile cases. For example, FIGS. 14-21 illustrateselected geometric features that can be constructed for aluminumsplashes having a rolling wave profile where there is no undercut andthe splash has no clearly defined outer edge. In the exampleconstruction depicted in FIGS. 14-21, the crevice/ball bond dimension Dis the horizontal distance from the crevice initiation point X to theouter edge of the ball bond base (e.g., 142). However, when the splashstructure (e.g., 143) is a rolling wave or sine wave type splash with noundercut, the crevice/splash dimension S may be defined as thehorizontal distance from the crevice initiation point X to the topmostpoint E of the rolling aluminum splash wave (e.g., 143). In addition,the crevice width EB may be constructed as the line EB drawn from thetopmost splash point E along a line that is perpendicular to the line Xa(which is drawn from the crevice point X through the topmost aluminumsplash point E) to the copper ball intersect point B. A crevice lengthX-Xd dimension may also be defined as the line drawn from the crevicepoint X to the midpoint Xd along the crevice width line EB. The crevicewidth α may be defined by angle EXB, or alternatively as the anglebetween line Xa and line Xb (drawn between the crevice point X and thecopper ball intersect point B). There may also be defined a lateralsplash size in terms of a lateral base distance (LB) from the creviceinitiation point (X) to the furthest point where the displaced aluminumpad is elevated above the top surface plane of the original aluminumpad. Finally, a splash index may be constructed by first defining asplash extension point T at the intersection point between thehorizontal tangent plane through the topmost splash point E and thesplash tangent line PT extending from the aluminum pad elevation pointP. Next, a vertical crevice extension point N is defined that is theperpendicular intersection between the top surface plane of the originalaluminum pad 141 and the vertical plane extending through the crevicepoint X. By drawing a splash extension line NT between the verticalcrevice extension point N and the splash extension point T, the crevicesplash index may be defined as the angle (β) between the splashextension line NT and the top surface plane of the original aluminum pad141.

With these geometric constructions in mind, a ninth case is shown in thecross-sectional view 14 of FIG. 14 which depicts a copper bond ball 142bonded to the aluminum bonding pad 141 formed on the integrated circuitdie 140. The depicted bonding forms a small wave-shaped splash structure143 having a convex shape that extends from a crevice initiation point Xthat is located above the top plane of the aluminum pad 141 (e.g.,H_(G)<H_(P)). To the extent that the lateral base length dimension (LB)extends slightly past the perimeter of the copper bond ball 142 and thecrevice/splash dimension S is less than the crevice/ball bond dimensionD, this is a relatively small wave splash structure 143. In addition,the resulting crevice 145 formed between the copper bond ball 142 andconvex wave splash structure 143 has a relatively short crevice widthEB, crevice angle α, and crevice length X-Xd which characterize areliable bond connection between the copper bond ball 142 and aluminumbonding pad 141.

In a tenth case shown in the cross-sectional view 15 of FIG. 15, acopper bond ball 152 is bonded to the aluminum bonding pad 151 formed onthe integrated circuit die 150. The depicted bonding forms a smallwave-shaped splash structure 153 having a concave shape that extendsfrom a crevice initiation point X that is located above the top plane ofthe aluminum pad 141 (e.g., H_(G)<H_(P)). With the crevice/splashdimension S being less than the crevice/ball bond dimension D, this is arelatively small wave splash structure 153. In addition, the resultingcrevice 155 formed between the copper bond ball 152 and concave wavesplash structure 153 has a relatively short crevice width EB, creviceangle α, and crevice length X-Xd which characterize a reliable bondconnection.

In an eleventh case shown in the cross-sectional view 16 of FIG. 16, acopper bond ball 162 is bonded to the aluminum bonding pad 161 formed onthe integrated circuit die 160. The depicted bonding forms a largewave-shaped splash structure 163 having a convex shape that extends froma crevice initiation point X that is located above the top plane of thealuminum pad 161 (e.g., H_(G)<H_(P)). With the crevice/splash dimensionS being larger than the crevice/ball bond dimension D and the lateralbase length dimension (LB) extending past the perimeter of the copperbond ball 162, this is a relatively large wave splash structure 163. Inaddition, the resulting crevice 165 formed between the copper bond ball162 and convex wave splash structure 163 has a relatively short crevicewidth EB, crevice angle α, and crevice length X-Xd which characterize areliable bond connection.

In a twelfth case shown in the cross-sectional view 17 of FIG. 17, acopper bond ball 172 is bonded to the aluminum bonding pad 171 formed onthe integrated circuit die 170. The depicted bonding forms a largewave-shaped splash structure 173 having a concave shape that extendsfrom a crevice initiation point X that is located above the top plane ofthe aluminum pad 171 (e.g., H_(G)<H_(P)). With the crevice/splashdimension S being larger than the crevice/ball bond dimension D and thelateral base length dimension (LB) extending past the perimeter of thecopper bond ball 172, this is a relatively large wave splash structure173. In addition, the resulting crevice 175 formed between the copperbond ball 172 and concave wave splash structure 173 has a relativelyshort crevice width EB, crevice angle α, and crevice length X-Xd whichcharacterize a reliable bond connection.

In a thirteenth case shown in the cross-sectional view 18 of FIG. 18, acopper bond ball 182 is bonded to the aluminum bonding pad 181 formed onthe integrated circuit die 180. The depicted bonding forms a smallsplash structure 183 having a convex shape that extends from a creviceinitiation point X that is located below the top plane of the aluminumpad 181 (e.g., H_(P)<H_(G)). With the crevice/splash dimension S beingless than the crevice/ball bond dimension D, this is a relatively smallwave splash structure 183. Compared to the example case shown in FIG.12, the crevice 185 formed between the copper bond ball 182 and theconvex splash structure 183 has a relatively long crevice length X-Xdwhich characterizes a relatively poor and unreliable bond connectionbetween the copper bond ball 182 and aluminum bonding pad 181 due to thereduced bond interface area and increased likelihood of mold compoundpenetration under the ball bond.

In a fourteenth case shown in the cross-sectional view 19 of FIG. 19, acopper bond ball 192 is bonded to the aluminum bonding pad 191 formed onthe integrated circuit die 190. The depicted bonding forms a smallsplash structure 193 having a concave shape that extends from a creviceinitiation point X that is located below the top plane of the aluminumpad 191 (e.g., H_(P)<H_(G)). With the crevice/splash dimension S beingless than the crevice/ball bond dimension D, this is a relatively smallwave splash structure 193. Compared to the example case shown in FIG.12, the crevice 195 formed between the copper bond ball 192 and theconcave splash structure 193 has a relatively long crevice length X-Xdwhich characterizes a relatively poor and unreliable bond connectionbetween the copper bond ball 192 and aluminum bonding pad 191 due to thereduced bond interface area and increased likelihood of mold compoundpenetration under the ball bond.

In a fifteenth case shown in the cross-sectional view 20 of FIG. 20, acopper bond ball 202 is bonded to the aluminum bonding pad 201 formed onthe integrated circuit die 200. The depicted bonding forms a largesplash structure 203 having a convex shape that extends from a creviceinitiation point X that is located below the top plane of the aluminumpad 201 (e.g., H_(P)=H_(G)). With the crevice/splash dimension S beinglarger than the crevice/ball bond dimension D, this is a relativelylarge wave splash structure 203. Compared to the example case shown inFIG. 12, the crevice 205 formed between the copper bond ball 202 and theconvex splash structure 203 has a relatively long crevice length X-Xdwhich characterizes a relatively poor and unreliable bond connectionbetween the copper bond ball 202 and aluminum bonding pad 201 due to thereduced bond interface area and increased likelihood of mold compoundpenetration under the ball bond.

In a sixteenth case shown in the cross-sectional view 21 of FIG. 21, acopper bond ball 212 is bonded to the aluminum bonding pad 211 formed onthe integrated circuit die 210. The depicted bonding forms a largesplash structure 213 having a concave shape that extends from a creviceinitiation point X that is located below the top plane of the aluminumpad 211 (e.g., H_(P)<H_(G)). With the crevice/splash dimension S beinglarger than the crevice/ball bond dimension D, this is a relativelylarge wave splash structure 213. Compared to the example case shown inFIG. 12, the crevice 215 formed between the copper bond ball 212 and theconcave splash structure 213 has a relatively long crevice length X-Xdwhich characterizes a relatively poor and unreliable bond connectionbetween the copper bond ball 212 and aluminum bonding pad 211 due to thereduced bond interface area and increased likelihood of mold compoundpenetration under the ball bond. In an example embodiment of the caseillustrated in FIG. 21, the crevice may have a relatively wide crevicewidth dimension EB=0.702 μm and relatively long crevice length dimensionX-Xd. In addition, a half width crevice dimension may be defined withreference to the mid-point V along the crevice length dimension X-Xd bydrawing a perpendicular line YZ at point V which intersects with thesplash structure 213 at point L and with the copper ball 212 at point R.In this example, the half width crevice dimension LR having a measure of0.152 μm is 21.6% of the crevice width dimension EB. The 21.6% valueindicates that the crevice width reduced by 78.4% in the first half ofthe crevice length. In another crevice, if the half width to mouth widthratio was 10%, this would indicate that the crevice narrows much morerapidly than in the first instance. Long crevices that narrow rapidlyindicate ball bonds with lower reliability in terms of ball bondinterface corrosion failure.

As will be appreciated, other geometric constructions may be used tocharacterize the copper ball bond attachment to the aluminum pad interms of the size, shape, and position of the aluminum splash featureand/or crevice formed thereby. For example and as illustrated in FIG.22, there is shown a cross-sectional view 22 of a copper bond ball 224that is bonded to the aluminum bonding pad 221 formed on the integratedcircuit die 220 to form a splash structure 223 having a concave shapethat extends from a crevice initiation point X that is located above thetop plane of the aluminum pad 221 (e.g., H_(G)<H_(P)). In this example,the length of the crevice or gap 225 may be defined as the distance fromstart of gap (the initiation point X) to end of gap. For the splashfeature (e.g., 223) that does not extend beyond the copper ball edge,the end of the crevice length XA may be defined as the intersectionpoint A between (1) the line extending from the crevice initiation pointX through the aluminum splash tangent point F, and (2) the perpendicularintersection line KC that is tangent to the aluminum splash tangentpoint K. In this case, the width of the gap or crevice may be measuredat predetermined intervals along the crevice length line XA defining thegap length. For example, the gap width may be characterized by usingperpendicular measurement lines at four measurement points taken at 25,50, 75, 100% along the gap length line XA to draw four lines across thegap that are perpendicular to the gap length line XA. In addition, thecrevice angle may be defined as the angle α enclosed by the two lines XAand XC from the gap initiation point X to the ends of maximum gap widthline (W100) (angle AXC). In addition to a splash height dimension(measuring the distance from the undeformed top surface of the aluminumpad 221 to the top of the splash feature 223), a splash length may bedefined with reference to a splash-ball tangent line drawn across boththe aluminum splash 223 and copper ball 224 by drawing a splash tangentline (not shown) from the crevice initiation point X that is tangent tothe splash feature 223, where the splash length is the distance alongthe splash tangent line from the crevice initiation point X to thesplash-ball tangent line. In addition to the vertical distance betweenthe gap initiation point X and the undeformed surface of the aluminumbonding pad 221, a vertical ball height measure may be defined as thevertical distance between the bottom of the copper ball 224 and theundeformed surface of the aluminum bonding pad 221.

To further illustrated selected embodiments of the present invention,reference is now made to FIG. 23 which is a simplified schematic flowchart 230 illustrating various methods for fabricating and testingdevices in accordance with selected embodiments of the invention. Indescribing the fabrication methodology 230, the description is intendedmerely to facilitate understanding of various exemplary embodiments andnot by way of limitation. Unless otherwise indicated, subsequent stepsmay be provided in any desired order. Since the steps illustrated inFIG. 23 and described below are provided by way of example only, it willbe appreciated that the sequence of illustrated steps may be modified,reduced or augmented in keeping with the alternative embodiments of thedisclosure so that the method may include additional steps, omit certainsteps, substitute or alter certain steps, or perform certain steps in anorder different than that illustrated in FIG. 23. Thus, it will beappreciated that the methodology of the present invention may be thoughtof as performing the identified sequence of steps in the order depicted,though the steps may also be performed in parallel, in a differentorder, or as independent operations that are combined.

Once the methodology starts (step 231), the copper wire is broughttowards the aluminum pad surface to initiate the bonding process (step232). The copper wire typically includes bonding ball is formed at anend of a bonding wire that may be applied by a capillary bonding tool.As the copper bonding ball contacts the aluminum pad surface, the shapeof the copper bonding ball may be deformed by the applied bonding force,or alternatively, the desired shape of the copper bonding ball may bepreformed or mechanically conditioned beforehand. In selectedembodiments, a Free Air Ball (FAB) may be formed on the end of thecopper wire from the plasma formed by the spark ignited by theElectronic Flame Off (EFO) system.

At step 233, the copper wire bonding balls are bonded directly to thealuminum pad surface layer using predetermined bonding parameters tocontrol the aluminum splash profile to have multiple optimized geometricfeatures. By properly selecting and controlling the bonding parametersas a combination of heat, pressure and ultrasonic energy to form anintermetallic connection or weld between a wire and a connection pad,the resulting aluminum splash profile will have a splash structure thatis formed around substantially the entire perimeter of the ball bond toa predefined limited extent where the elevated splash pad dimension (LB)is less than or equal to twice the outermost lateral splash lengthdimension (LS), and where the splash-ball crevice is positioned abovethe top of the undeformed aluminum pad, thereby minimizing opportunitiesfor undesirable mold compound penetration. In addition, the selectedbonding parameters are controlled to prevent mold compound penetrationby forming short crevice lengths, narrow crevice widths, and acrevice-pad splash index (β) within a predetermined range (e.g., of20-75°). Copper ball bonding reliability is also promoted by controllingthe selected bonding parameters so that the splash height (H_(P)) isless than half the ball height and greater than half the aluminum padthickness.

In an example embodiment where the selected bonding parameters at step243 are optimized for an ASM wire bonder to form reliable copper ballbonds to an aluminum bond pad (99.5% Al+0.5 wt % Cu) having a thicknessof 1.2 um with bond pad opening of 59 um as the smallest side is shownbelow:

-   -   a. The bonding temperature is 170° C. as preheat, 200° C. at        bonding temperature and post bond temperature 150° C.;    -   b. Standby power (USG current, mA): 35.2 to 37.2    -   c. Bonding power (USG current, mA): 88 to 93;    -   d. Initial bonding force: 15 g;    -   c. Bonding force: 40 to 45 g; and    -   f. Bonding time: 20 m-sec.

As will be appreciated, two types of bonding concepts can be used toachieve the various bonding profile cases illustrated in the figures,where there are generally two bonding segments used during the bondingprocesses. The first bonding concept is turning on bonding force withzero bonding power during the first segment, and to use minimal bondingforce and optimal bonding power during the second segment. The secondbonding concept used to achieve Cases 1 through 16 (illustrated, inFIGS. 6-21) is the use of mid-range bonding power and optimal bondingforce during the first segment, and lower bonding force and optimalbonding power during the second segment. It will also be appreciatedthat the effect of the various bonding parameters on achieving theexample features illustrated for Cases 1-16 will be modulated by theclamping system used to hold the integrated circuit die assembly in thewire bonding system, the material features and properties of theassembly elements, the material features and properties of the copperwire, the bonding temperature, and the capillary material and design. Ingeneral, it is best to firmly clamp the assembly as close to the bondingarea as possible. The thickness of the die, and the composition,thickness, and hardness of the aluminum bond pad metal affects theresulting copper ball bond. Higher temperatures are commonly used (≧200°C.) when copper wire bonding on a metal lead frame assembly, while lowertemperatures (≦180° C.) are commonly used when copper wire bonding on aprinted circuit board substrate assembly. The thickness and physical andmechanical properties of the lead frame metal, and the thickness ofindividual metal and dielectric layers in the printed circuit boardsubstrate, and properties of these layers, affect heat transfer andattenuation of ultrasonic energy during the bonding process. The copperwire may be an uncoated, high purity copper alloy, or it may be coatedwith another metal such as palladium, gold, or silver. The physical andmechanical properties of the free air ball (FAB) affect the interactionwith the aluminum pad metal. The capillary material and design affectsthe efficiency of transfer of energy from the capillary to the ball bondduring its formation which affects the quality of the bond to thealuminum pad.

The following explanation is provided to describe how of the variousbonding parameters can be controlled to achieve the example featuresillustrated for Cases 1-16. Compared to the bonding parameter set usedto form the bonding profile of Case 1 (FIG. 6), Case 2 (FIG. 7) can beachieved by increasing bonding power and turning off, or reducingpre-bleed. Pre-bleed refers to the level of ultrasonic energy applied tothe capillary prior to the initial contact of the copper free air ball(FAB). This means ultrasonic energy is turned on before the FAB touchesthe aluminum bond pad while maintaining the same level of bonding force.Cases 1 and 2 can be easily achieved by the first bonding concept, whileCase 3 (FIG. 8) may be more readily achieved using the second bondingconcept during the first and second bonding segments as described above.Case 4 (FIG. 9) conditions may be achieved by increasing the bondingforce used in the Case 3 parameter set. Cases 5 and 6 (FIGS. 10 and 11)can be made by increasing both bonding force and bonding power usingCase 1 and 2 bonding concepts, respectively, with zero pre-bleed. Toachieve the bonding profile of Case 6 (FIG. 11), the bonding force isincreased to a higher level than that used in the Case 5 (FIG. 10)setting. And for Cases 7 and 8 (FIGS. 12 and 13), much higher bondingforce and power is applied during both bonding segments. For example,this may be required when bonding harder aluminum layers, or whenbonding onto aluminum pads that have a thicker aluminum oxide surfacelayer. Cases 9 to 16 require a different capillary design using achamfer angle designed to keep more of the FAB inside the chamfer sidewall of the tip of capillary than is used for Cases 1 to 8, and can bemore easily achieved with the second bonding concept. As will beappreciated, minimum levels of bonding power and bonding force generallyproduce aluminum splash where distance ‘D’ is less than distance ‘S’.When bonding power is optimal, higher levels of bonding force tend tomove point ‘X’ lower than point ‘N’. The crevice width EB for Cases 9 to16 depends strongly on aluminum thickness and hardness in addition tobonding parameters. Use of a relatively lower bonding force and lowerbonding power than those used in previous cases can produce featuresshown in Case 9. Case 10 can be achieved by increasing bonding forceduring the first segment of bonding process, or reducing the pre-bleedsetting. Cases 11 and 12 require higher bonding power and force thanCase 9 and 10 using the same bonding concept. Case 12 can be formed withhigher bonding force than used in Case 11, or with use of a lowerpre-bleed setting. Cases 13 to 16 can be made with use of higher bondingforce and power levels than used for Case 9 to 12. Case 14 may be formedwith use of a higher bonding force and lower pre-bleed than level thanused in Case 13. Case 15 and 16 may be the result of turning off thepre-bleed, increasing bonding force and decreasing bonding power duringthe first bonding segment.

Of course, it will be understood that the present invention is notlimited to a particular set of bonding parameters. Rather, the optimumbonding parameters are dependent on wire type, pad metallization, deviceconfigurations, and other consideration.

Once the bonding of the copper balls and aluminum pads is completed, theindividual devices are encapsulated with a transfer mold compounds atstep 231. Transfer molding may be used to mold thermoset materials byfeeding material into a cavity with simple plunger action on the meltedthermoset material.

At this point, the transfer mold material can penetrate into the creviceor gap between the copper ball and aluminum splash feature. And if thecrevice is too deep, the transfer mold material can penetrate anundesirable distance under the ball bond, possibly damaging or crateringthe aluminum pad.

After packaging the integrated circuit device, the integrated circuitdevice may be tested at step 235, either with a stress test or a visualtest to evaluate the geometric structures of the copper ball bond. Aswill be appreciated, any stress test may be applied, including but notlimited to biased HAST, unbiased HAST, THB, autoclave, and temperaturecycling testing. In addition or in the alternative, it will beappreciated that inspection and testing of the copper ball bondgeometric features may be performed after bonding of the copper ballsand aluminum pads is completed and before molding. If performed aftermolding, the transfer mold compound must be removed with acids or otherremoval techniques. In addition or in the alternative, the variousgeometric structural features described herein may be assessed by use ofstandard tools and procedures for failure analysis of semiconductordevices, to measure aspects of the aluminum splash and associatedcrevice or gap, and/or crevice splash index angle of the aluminum splashin relation to the aluminum pad. Next, the test results are assessed atstep 236. If the integrated circuit device passes 238 (affirmativeoutcome to decision 236), the next device may be selected (step 239) forapplication of the test (step 235). However, if the integrated circuitdevice fails the test 237 (negative outcome to decision 237), and thetest may then be performed on the next device (step 239).

By now it should be appreciated that there is provided herein anintegrated circuit wire bond connection and method for manufacturingsame. As disclosed, the copper bond wire includes a copper ball and analuminum bond pad that is directly bonded to the copper ball to form analuminum splash structure and associated crevice opening between thealuminum splash structure and copper ball and substantially around theentire peripheral bond edge of the copper ball, where the aluminumsplash structure is characterized by a first plurality of geometricproperties or features indicative of a reliable copper ball bond whichare controlled to be within a predetermined range of values. When thecopper ball is attached to the aluminum bond pad by applying ultrasonicvibration energy to the copper ball in a first direction, the resultinggeometric features may include larger geometric features evaluated in across section that is parallel to the first direction and smallergeometric features evaluated in a cross section that is perpendicular tothe first direction. In selected embodiments, the first plurality ofgeometric properties or features for the aluminum splash structureincludes a lateral splash size measure (LS) of the lateral extent of thealuminum splash structure which extends at least substantially to, butnot substantially past, an outer perimeter of the copper ball; a splashheight measure (HS) of the vertical distance from a top surface of thealuminum bond pad to a top surface of the aluminum splash structure thatis less than half a ball bond height measure for the copper ball andmore than half an original pad thickness measure for the aluminum bondpad; and a gap height measure (H_(G)) of the vertical distance from alowest point of the crevice opening to the top surface of the aluminumsplash structure that is less than the splash height measure. The firstplurality of geometric properties for the aluminum splash structure mayalso include an elevated splash pad measure of the lateral extent of abase portion of the aluminum splash structure that is less than or equalto twice the lateral splash size measure. In other embodiments, thecrevice opening between the aluminum splash structure and copper ball ischaracterized by a second plurality of geometric properties indicativeof a reliable copper ball bond, including a crevice initiation planeintersecting the lowest point of the crevice opening and positionedabove a top surface of the aluminum bond pad; and a crevice mouth widthmeasure and a crevice length measure, where a ratio of the crevice mouthwidth measure to the crevice length measure is greater than or equal to0.1. In some embodiments, the crevice mouth width is measured along afirst tangent line from a first tangent intersection point on thealuminum splash structure to a second tangent intersection point on thecopper ball, and the crevice length measure is measured along a linefrom the lowest point of the crevice opening to a midpoint on the firsttangent line. In other embodiments, the crevice mouth width is measuredalong a first tangent line (1) that extends from a first tangentintersection point on the aluminum splash structure to a secondintersection point on the copper ball, and (2) that is perpendicular toa second tangent line extending from the lowest point of the creviceopening to a second tangent intersection point on the aluminum splashstructure; and the crevice length measure is measured along a line fromthe lowest point of the crevice opening to the first tangent line. Inother embodiments, the crevice mouth width is measured along a firstline from a topmost point on the aluminum splash structure to anintersection point on the copper ball, where the first line isperpendicular to a second line extending from the lowest point of thecrevice opening to the topmost point on the aluminum splash structure,and where the crevice length measure is measured along a line from thelowest point of the crevice opening to a midpoint on the first line. Thealuminum splash structure may also be characterized by a crevice-padsplash index angle within a range of 20-75°, where the crevice-padsplash index angle is included between (1) a first line defining a topsurface of the aluminum bond pad and intersecting with a vertical lineintersecting the lowest point of the crevice opening at a verticalcrevice extension point N, and (2) a second splash extension line fromthe vertical crevice extension point N to a splash extension point Mthat is at a perpendicular intersection between horizontal and verticaltangent planes intersecting the aluminum splash structure. In otherembodiments, the aluminum splash structure is characterized by acrevice-pad splash index angle within a predetermined range that isincluded between (1) an aluminum bond pad surface line parallel to a topsurface of the aluminum bond pad and extending from an aluminum padelevation point P to intersect with a vertical line intersecting thelowest point of the crevice opening at a vertical crevice extensionpoint N, and (2) a splash extension line from the vertical creviceextension point N to a splash extension point T that is at anintersection between (a) a horizontal extending through the topmostpoint on the aluminum splash structure, and (b) and a tangent lineextending from the aluminum pad elevation point P to a tangentintersection point on the aluminum splash structure. The plurality ofgeometric properties may include one or more geometric properties forinner and outer segments of the aluminum splash structure in a firstcross section that is parallel to movement of a wire bond transducerused to bond the copper ball bond to the aluminum bond pad, and one ormore geometric properties for lateral segments of the aluminum splashstructure in a second cross section that is transverse to movement ofthe wire bond transducer used to bond the copper ball bond to thealuminum bond pad.

In another form, there is provided a method of forming a copper ballbond. As an initial step, a bonding wire is formed that includes acopper ball, and the copper ball is then positioned at a bonding site atan aluminum bond pad. Thereafter, the copper ball is bonded to analuminum bond pad with a predetermined combination of heat, pressure andultrasonic vibration energy applied in a first direction. In an exampleimplementation, the combination of heat, pressure and ultrasonicvibration energy includes preheating the bonding wire an copper ball toa preheat temperature of approximately is 170° C.; and heating thecopper ball and aluminum bond pad to a bonding temperature ofapproximately 200° C. when bonding the copper ball to the aluminum bondpad while supplying bonding power current of approximately 88 to 93 mAand applying a bonding force of approximately 40-45 g during a bondingtime of approximately 20 msec. As a result, an intermetallic connectionlayer is formed between the copper ball and the aluminum bond pad and analuminum splash structure and associated crevice opening between thealuminum splash structure and the copper ball, where the aluminum splashstructure is characterized by a first plurality of geometric featuresindicative of a reliable copper ball bond, comprising a first pluralityof larger geometric features evaluated in a cross section that isparallel to the first direction and a second plurality of smallergeometric features evaluated in across section that is transverse to thefirst direction. For example, the geometric features for the aluminumsplash structure may include a lateral splash size measure of thealuminum splash structure which extends at least substantially to, butnot substantially past, an outer perimeter of the copper ball; avertical splash height measure from a top surface of the aluminum bondpad to a top surface of the aluminum splash structure that is less thanhalf a ball bond height measure for the copper ball and more than halfan original pad thickness measure for the aluminum bond pad; a verticalgap height measure from a lowest point of the crevice opening to the topsurface of the aluminum splash structure that is less than the verticalsplash height measure; and a crevice-pad splash index angle that iswithin a range of 20-75°. In addition, the crevice opening may becharacterized by a plurality of geometric features indicative of areliable copper ball bond, including a crevice initiation planeintersecting the lowest point of the crevice opening and positionedabove the top surface of the aluminum bond pad; and a crevice mouthwidth measure and a crevice length measure, where a ratio of the crevicemouth width measure to the crevice length measure is greater than orequal to 0.1. In selected embodiments, the crevice mouth width ismeasured along a first tangent line (1) that extends from a firsttangent intersection point on the aluminum splash structure to a secondintersection point on the copper ball, and (2) that is perpendicular toa second tangent line extending from the lowest point of the creviceopening to a second tangent intersection point on the aluminum splashstructure; and where the crevice length measure is measured along a linefrom the lowest point of the crevice opening to a midpoint on the firsttangent line.

Although the described exemplary embodiments disclosed herein aredirected to various geometric features and structures for a copper ballbond to an aluminum pad and methods for making same, the presentinvention is not necessarily limited to the example embodiments whichillustrate inventive aspects of the present invention that areapplicable to a wide variety of transistor fabrication processes and/orstructures. For example, the direct bonding of copper bond balls toaluminum connection pads provides equivalent or superior reliability togold wire bonding to the same package because the copper-aluminumintermetallic is thinner and more robust than the gold-aluminumintermetallic, but selected embodiments may also form reliable bondswith noble metal doped copper wires when the ball bond geometric shapeis properly controlled to form aluminum splash structures. Thus, theparticular embodiments disclosed above are illustrative only and shouldnot be taken as limitations upon the present invention, as the inventionmay be modified and practiced in different but equivalent mannersapparent to those skilled in the art having the benefit of the teachingsherein. Accordingly, the foregoing description is not intended to limitthe invention to the particular form set forth, but on the contrary, isintended to cover such alternatives, modifications and equivalents asmay be included within the spirit and scope of the invention as definedby the appended claims so that those skilled in the art shouldunderstand that they can make various changes, substitutions andalterations without departing from the spirit and scope of the inventionin its broadest form.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any element(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature or element of any or all the claims. As used herein, the terms“comprises,” “comprising,” or any other variation thereof, are intendedto cover a non-exclusive inclusion, such that a process, method,article, or apparatus that comprises a list of elements does not includeonly those elements but may include other elements not expressly listedor inherent to such process, method, article, or apparatus.

What is claimed is:
 1. An integrated circuit wire bond connectioncomprising: a copper bond wire comprising a copper ball and an aluminumbond pad that is directly bonded to the copper ball to form an aluminumsplash structure and associated crevice opening between the aluminumsplash structure and copper ball at a peripheral bond edge of the copperball, where the aluminum splash structure is characterized by a firstplurality of geometric features indicative of a reliable copper ballbond comprising: a splash height measure of the vertical distance from atop surface of the aluminum bond pad to a top surface of the aluminumsplash structure that is less than half a ball bond height measure forthe copper ball and more than half an original pad thickness measure forthe aluminum bond pad; and a gap height measure of the vertical distancefrom a lowest point of the crevice opening to the top surface of thealuminum splash structure that is less than eighty percent of the splashheight measure.
 2. The integrated circuit wire bond connection of claim1, where the original pad thickness measure for the aluminum bond pad isless than 1.5μm.
 3. The integrated circuit wire bond connection of claim1, where the splash height measure is more than twice the original padthickness measure for the aluminum bond pad.
 4. The integrated circuitwire bond connection of claim 1, where the gap height measure is lessthan seventy-five percent of the splash height measure.
 5. Theintegrated circuit wire bond connection of claim 1, where the firstplurality of geometric features comprises a lateral splash size measureof a lateral extent of the aluminum splash structure which extends atleast substantially to, but not substantially past, an outer perimeterof the copper ball.
 6. The integrated circuit wire bond connection ofclaim 5, where the aluminum splash structure is formed aroundsubstantially an entirety of the outer perimeter of the copper ball. 7.The integrated circuit wire bond connection of claim 1, where the firstplurality of geometric features for the aluminum splash structurecomprises an elevated splash pad measure of a lateral extent of a baseportion of the aluminum splash structure that is less than or equal totwice the lateral splash size measure.
 8. The integrated circuit wirebond connection of claim 1, where the crevice opening is characterizedby a second plurality of geometric features comprising a crevice mouthwidth measure and a crevice length measure, where a ratio of the crevicemouth width measure to the crevice length measure is between 0.3 and0.4.
 9. An integrated circuit wire bond connection comprising: a copperbond wire comprising a copper ball and an aluminum bond pad that isdirectly bonded to the copper ball to form an aluminum splash structureand associated crevice opening between the aluminum splash structure andcopper ball at a peripheral bond edge of the copper ball, where thealuminum splash structure is characterized by a first plurality ofgeometric features comprising an elevated splash pad measure of alateral extent of a base portion of the aluminum splash structure thatis greater than the lateral splash size measure and less than or equalto twice the lateral splash size measure.
 10. The integrated circuitwire bond connection of claim 8, where the crevice mouth width ismeasured along a first tangent line from a first tangent intersectionpoint on the aluminum splash structure to a second tangent intersectionpoint on the copper ball, and where the crevice length measure ismeasured along a line from the lowest point of the crevice opening to amidpoint on the first tangent line.
 11. The integrated circuit wire bondconnection of claim 8, where the crevice mouth width is measured along afirst tangent line (1) that extends from a first tangent intersectionpoint on the aluminum splash structure to a second intersection point onthe copper ball, and (2) that is perpendicular to a second tangent lineextending from the lowest point of the crevice opening to a secondtangent intersection point on the aluminum splash structure; and wherethe crevice length measure is measured along a line from the lowestpoint of the crevice opening to the first tangent line.
 12. Theintegrated circuit wire bond connection of claim 9, where the firstplurality of geometric features comprises: a splash height measure ofthe vertical distance from a top surface of the aluminum bond pad to atop surface of the aluminum splash structure that is less than half aball bond height measure for the copper ball and more than half anoriginal pad thickness measure for the aluminum bond pad; and a gapheight measure of the vertical distance from a lowest point of thecrevice opening to the top surface of the aluminum splash structure thatis less than 80 percent of the splash height measure.
 13. The integratedcircuit wire bond connection of claim 9, where the crevice opening ischaracterized by a second plurality of geometric features comprising acrevice mouth width measure and a crevice length measure, where a ratioof the crevice mouth width measure to the crevice length measure isbetween 0.3 and 0.4.
 14. An integrated circuit wire bond connectioncomprising: a copper bond wire comprising a copper ball and an aluminumbond pad that is directly bonded to the copper ball to form an aluminumsplash structure and associated crevice opening between the aluminumsplash structure and copper ball at a peripheral bond edge of the copperball, where the aluminum splash structure is characterized by a firstplurality of geometric features indicative of a reliable copper ballbond, and where the crevice opening between the aluminum splashstructure and copper ball is characterized by a second plurality ofgeometric features comprising: a crevice initiation plane intersectingthe lowest point of the crevice opening and positioned above a topsurface of the aluminum bond pad; and a crevice mouth width measure anda crevice length measure, where a ratio of the crevice mouth widthmeasure to the crevice length measure is between 0.1 and 0.5.
 15. Theintegrated circuit wire bond connection of claim 14, where the ratio ofthe crevice mouth width measure to the crevice length measure is greaterthan 0.3.
 16. The integrated circuit wire bond connection of claim 15,where the ratio of the crevice mouth width measure to the crevice lengthmeasure is less than 0.4.
 17. The integrated circuit wire bondconnection of claim 14, where the first plurality of geometric featurescomprises: a splash height measure of the vertical distance from a topsurface of the aluminum bond pad to a top surface of the aluminum splashstructure that is less than half a ball bond height measure for thecopper ball and more than half an original pad thickness measure for thealuminum bond pad; and a gap height measure of the vertical distancefrom a lowest point of the crevice opening to the top surface of thealuminum splash structure that is less than 80 percent of the splashheight measure.
 18. The integrated circuit wire bond connection of claim14, where the first plurality of geometric features for the aluminumsplash structure comprises an elevated splash pad measure of a lateralextent of a base portion of the aluminum splash structure that is lessthan or equal to twice the lateral splash size measure.